MR VACUTAP VV-Ex Installation And Commissioning Instructions Download Page 64

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5 Mounting

Maschinenfabrik Reinhausen GmbH 2020

4983703/01 EN

VACUTAP

VV-Ex

5.4.6 Lifting top part of on-load tap-changer head off supporting

flange (bottom part)

WARNING

Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.

► Ensure that there are no ignition sources such as open flames, hot sur-

faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.

► De-energize all auxiliary circuits (for example tap-change supervisory de-

vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.

► Do not operate any electrical devices during the work (e.g. risk of sparks

from impact wrench).

NOTICE

Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.

► Ensure that parts do not fall into the oil compartment.

► Check that all small parts are accounted for.

1. Ensure that the on-load tap-changer is in the adjustment position. The ad-

justment position is indicated in the on-load tap-changer connection dia-
gram included in delivery.

2. Ensure that the inspection window is sealed off with the cover.

3. Remove temporary fastening and spacers and slowly lower the on-load

tap-changer.

Figure 37: Temporary fastening

Summary of Contents for VACUTAP VV-Ex

Page 1: ...On load tap changer VACUTAP VV Ex Installation and commissioning instructions 4983703 01 EN ...

Page 2: ... for compensation All rights reserved in the event of the granting of patents utility models or designs The product may have been altered since this document was published We reserve the right to change the technical data design and scope of supply Generally the information provided and agreements made when processing the individual quotations and orders are binding The original operating instruct...

Page 3: ...lication range of the on load tap changer 14 2 4 2 Standards and regulations 16 2 5 Measures for ensuring compliance with explosion protection requirements 17 2 5 1 Measures taken by the manufacturer 17 2 5 2 Measures to be taken by the transformer manufacturer operator 17 2 6 Personnel qualification 20 2 7 Personal protective equipment 22 3 Product description 23 3 1 Scope of delivery 23 3 2 On l...

Page 4: ...ormer tank 53 5 3 7 Filling the oil compartment of the on load tap changer with insulating fluid 56 5 3 8 Performing transformer ratio test after drying 57 5 4 Installing on load tap changer in transformer bell type tank version 58 5 4 1 Inserting on load tap changer into supporting structure 58 5 4 2 Connecting the tap winding and on load tap changer take off lead 60 5 4 3 Performing transformer ...

Page 5: ...nsport with empty transformer tank 118 6 3 Commissioning transformer at operating site 120 6 3 1 Filling the oil compartment of the on load tap changer with insulating fluid 120 6 3 2 Bleeding on load tap changer head and suction pipe 121 6 3 3 Checking motor drive unit 123 6 3 4 Checking protective relay 124 6 3 5 Commissioning the transformer 125 7 Fault elimination 126 7 1 Tripping the protecti...

Page 6: ...Dimensions of oil suction pipe not supplied by MR 734342 140 9 7 Tracing template for on load tap changer head 893787 141 9 8 Mounting drawing 898866 142 9 9 Mounting with bell type tank installation 899110 143 9 10 Position of on load tap changer 899409 144 9 11 Position of connection contacts 899051 145 9 12 Tap change supervisory control 733469 146 9 13 Bevel gear CD 6400 dimensional drawing 89...

Page 7: ...nfabrik Reinhausen GmbH Falkensteinstraße 8 93059 Regensburg Tel 49 9 41 40 90 0 E mail sales reinhausen com Further information on the product and copies of this technical file are avail able from this address if required 1 2 Completeness This technical file is incomplete without the supporting documents The following documents are considered supporting documents Unpacking instructions Supplement...

Page 8: ...ngs relating to sec tions Embedded warnings use the following format DANGER Instruction for avoiding a dangerous situation 1 4 1 3 Signal words and pictograms The following signal words are used Signal word Definition DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death ...

Page 9: ...derstanding of particular procedures In this technical file it is laid out as follows Important information 1 4 3 Instruction system This technical file contains single step and multi step instructions Single step instructions Instructions which consist of only a single process step are structured as fol lows Aim of action ü Requirements optional Step 1 of 1 ð Result of step optional ð Result of a...

Page 10: ...uction Maschinenfabrik Reinhausen GmbH 2020 10 4983703 01 EN VACUTAP VV Ex Aim of action ü Requirements optional 1 Step 1 ð Result of step optional 2 Step 2 ð Result of step optional ð Result of action optional ...

Page 11: ...nstallation and operation to removal and disposal The following is considered appropriate use Use the product only with the transformer specified in the order Only operate the product with the versions of the motor drive unit drive shaft and protective relay that have been approved for use in explosive ar eas The serial numbers of on load tap changer and on load tap changer ac cessories drive driv...

Page 12: ...plies to the affected transformer itself just as it does to transformers electrically connected in parallel or serially or other electrical machines Higher voltages may occur due to transformer overexcitation following load shedding for example Operations outside of the permitted operating conditions can lead to injury to persons and damage to the product Prevent any such operations outside of the...

Page 13: ...losive atmospheres Safety markings Warning signs and safety information plates are safety markings on the product They are an important aspect of the safety concept Observe all safety markings on the product Make sure all safety markings on the product remain intact and legible Replace safety markings that are damaged or missing Ambient conditions To ensure reliable and safe operation the product ...

Page 14: ...ith Maschinenfabrik Rein hausen GmbH Spare parts Spare parts not approved by Maschinenfabrik Reinhausen GmbH may lead to physical injury damage to the product and malfunctions Only use spare parts that have been approved by Maschinenfabrik Rein hausen GmbH Contact Maschinenfabrik Reinhausen GmbH 2 4 Standards and regulations 2 4 1 Application range of the on load tap changer The on load tap change...

Page 15: ...present continuously for long periods or frequently 2G 1 2D 21 Equipment in this category is intended for use in ar eas in which explosive atmospheres caused by gases vapors mists or air dust mixtures occur oc casionally 3G 2 3D 22 Equipment in this category is intended for use in ar eas in which explosive atmospheres caused by gases vapors mists or air dust mixtures are un likely to occur or if t...

Page 16: ...50 C T3 200 C 200 C 300 C T4 135 C 135 C 200 C T5 100 C 100 C 135 C T6 85 C 85 C 100 C Table 8 Temperature classes Equipment protection level EPL number 8 The EPL indicates the level of protection defined for a device based on the level of probability of ignition and taking into account the differences be tween potentially explosive gas atmospheres potentially explosive dust at mospheres and poten...

Page 17: ...compartment A temperature sensor is provided in the on load tap changer head cover for monitoring the oil temperature in the diverter switch oil compartment The corresponding temperature monitoring relay is in the TAPMOTION ED Ex Temperature monitoring prevents further switching of the on load tap changer when the maximum permitted temperature is reached This maxi mum permitted temperature is fact...

Page 18: ...g oil is present in the diverter switch oil compartment at all times Figure 1 On load tap changer oil system 1 Diverter switch oil compartment 5 Signaling contacts 2 Temperature sensor 6 Oil conservator 3 Protective relay 7 Dehydrating breather 4 Level indicator 2 5 2 3 Oil conservator to be used The oil conservator of the on load tap changer ensures that sufficient insu lating oil is present in t...

Page 19: ...he circuit breaker will immediately de energize the transformer when the oil level in the oil conservator falls below this minimum 2 5 2 3 4 Insulating oil to be used When filling the diverter switch oil compartment and its oil conservator use only new mineral insulating oil for transformers in accordance with IEC 60296 Specification for unused mineral insulating oils for transformers and switchge...

Page 20: ...lly painted The contact surface of the on load tap changer head is primed ex factory The through holes are primed and partially painted The transformer manufacturer is responsible for the design of the mating surfaces on the transformer and piping and that of the screw connections needed for these attachments 1 Provide suitable sealing to prevent electrolytes from entering sealing sur faces and ho...

Page 21: ...nd the poten tial dangers in the event of inappropriate handling as well as the protective devices and safety measures The electrically trained person works exclu sively under the guidance and supervision of an electrically skilled person Operator The operator uses and operates the product in line with this technical file The operating company provides the operator with instruction and training on...

Page 22: ... a low tearing strength with tight sleeves and with no protruding parts It mainly serves to protect the wearer against being caught by moving machine parts Safety shoes To protect against falling heavy objects and slipping on slippery surfaces Safety glasses To protect the eyes from flying parts and splashing liq uids Visor To protect the face from flying parts and splashing liq uids or other dang...

Page 23: ... a dry place until installation The product must remain in its airtight protective wrapping and may only be removed immediately before installation You will find more information in the Packaging transport and stor age Section 4 Page 35 chapter 3 2 On load tap changer 3 2 1 Function description On load tap changers are used to adjust the transmission ratio of transform ers without interrupting the...

Page 24: ...w of on load tap changer transformer 1 Transformer tank 6 Gear unit 2 Motor drive unit 7 On load tap changer 3 Vertical drive shaft 8 Protective relay 4 Bevel gear 9 Oil conservator 5 Horizontal drive shaft 10 Active part 3 2 2 Setup models The following drawing shows the main components of the on load tap changer ...

Page 25: ...p changer in the Drawings Section 9 Page 135 section Figure 4 On load tap changer 1 Upper gear unit 2 On load tap changer head 3 Supporting flange 4 Connection contact 5 Oil compartment 6 Change over selector 7 Pipe bend 8 Rupture disk 3 2 2 1 Pipe connections The on load tap changer head features 4 pipe connections for different pur poses ...

Page 26: ...height If the on load tap changer is fitted with an oil suc tion pipe the on load tap changer can be completely emptied via pipe con nection S Pipe connection R Pipe connection R is intended for attachment of the protective relay and con nection of the on load tap changer oil conservator and can be interchanged with pipe connection Q Pipe connection E2 Pipe connection E2 is sealed off with a blank...

Page 27: ...d tap changer head to the oil conservator is exceeded due to a fault The flowing insulating fluid actuates the flap valve which tips over into position OFF The contact in the dry reed magnetic switch is thereby actuated the circuit breakers are tripped and the trans former is de energized The protective relay is a component of an on load tap changer filled with in sulating fluid and its properties...

Page 28: ...enfabrik Reinhausen GmbH 2020 28 4983703 01 EN VACUTAP VV Ex 3 2 4 1 2 Setup versions Front view Figure 7 RS 2001 Ex 1 Inspection window 2 Pressure equalization element Rear view Figure 8 RS 2001 Ex 1 Ground connection 2 Nameplate ...

Page 29: ... Slotted head screw for potential tie in 5 OPERATION reset test button 6 Slotted head screw for protective cover 7 OFF test tripping test button 8 Protective conductor connection 9 Protective cover 10 Dummy plug 11 Connection terminal 3 2 4 1 3 Name plate The name plate for the explosion protected protective relay is on the rear of the product Figure 10 Position of name plate ...

Page 30: ...ger 3 2 4 3 Temperature monitoring The temperature monitoring system monitors the temperature of the insulat ing fluid in the oil compartment of the on load tap changer 3 3 Drive shaft 3 3 1 Function description The drive shaft is the mechanical connection between the drive and the on load tap changer head The bevel gear changes the direction from vertical to horizontal Accordingly the vertical dr...

Page 31: ...VACUTAP VV Ex The explosion proof drive shaft consists of a square tube with insulator and is coupled by two coupling brackets and one coupling bolt at both ends to the drive or driven shaft end of the device to be connected Figure 11 Explosion proof drive shaft with insulator ...

Page 32: ...l The design of the explosion proof drive shaft is described in this section Figure 12 Components of the explosion proof drive shaft 1 Bevel gear 2 Hose clip 3 Screws 4 Telescopic protective tube 5 Coupling bracket 6 Insulator 7 Double coupling bracket 8 Square tube 9 Pin 10 Adapter ring 11 Protective cover ...

Page 33: ...iguration V 1 min Intermediate bearing Middle of hand crank middle of bevel gear maximum permissible axial offset 2 706 mm If the maximum value of 2472 mm is exceeded the use of an intermediate bearing is necessary V 1 2472 mm without in termediate bearing V 1 2472 mm with inter mediate bearing ...

Page 34: ...scription Maschinenfabrik Reinhausen GmbH 2020 34 4983703 01 EN VACUTAP VV Ex 3 3 3 Identification plate The identification plate is on the telescopic protective tube Figure 13 Position of the identification plate ...

Page 35: ... marking on the packaging states if for example the on load tap changer or selector has been packed upright Never stack these crates General rule Do not stack crates above a height of 1 5 m For other crates Only stack up to 2 equally sized crates on top of one an other The packaging is suitable to ensure undamaged and fully functional means of transportation in compliance with local transportation...

Page 36: ...allet secure it sufficiently Only trained and authorized persons may select the sling gear and se cure the load Do not walk under the suspended load Use means of transport and lifting gear with a sufficient carrying capacity in accordance with the weight stated on the delivery slip In addition to oscillation stress jolts must also be expected during trans portation In order to prevent possible dam...

Page 37: ...kaging is damaged do not under any circumstances install or commission the packaged goods Either re dry the dried packaged goods as per the operating instructions or contact the manufacturer to agree on how to proceed Identify the damaged parts Hidden damage When damages are not determined until unpacking after receipt of the ship ment hidden damage proceed as follows Make the party responsible fo...

Page 38: ...ackaging to lose its sealing function If the product is installed more than 6 months after delivery suitable mea sures must be taken without delay The following measures can be used Correctly regenerate the drying agent and restore the sealed packaging Unpack the packed goods and store in a suitable storage space well ven tilated as dust free as possible humidity 50 where possible 4 4 Unpacking sh...

Page 39: ...o not reach into the selector change over selector or potential connec tion unit during tap change operations Do not switch the on load tap changer during work on the selector change over selector or potential connection unit 5 1 Installation information Note the following information for the installation 1 Use the lifting straps provided to unpack and for transport by crane 2 During installation ...

Page 40: ...transformer 5 2 1 Fitting mounting flange on transformer cover A mounting flange is required for fitting the on load tap changer head on the transformer cover This can be supplied as an option or can be produced by the customer Mounting flanges made by the customer must comply with the installation drawings in the appendix NOTICE Fit mounting flange on transformer cover pressure tight En sure that...

Page 41: ...ng flange Figure 15 Tracing template stud bolts 5 3 Installing the on load tap changer in the transformer standard version 5 3 1 Fastening on load tap changer to transformer cover Note that only on load tap changers with an unscrewed supporting flange can be fitted in a transformer with the standard design ...

Page 42: ...or 1 CAUTION An unstably positioned on load tap changer may tip re sulting in serious injuries and damage Place on load tap changer on a level surface and secure it against tipping 2 Remove red colored packaging material and transport material from on load tap changer 3 Ensure that the on load tap changer is in the adjustment position The ad justment position is indicated in the on load tap change...

Page 43: ...2020 43 4983703 01 EN VACUTAP VV Ex 6 Remove on load tap changer head cover Figure 17 On load tap changer head cover 7 For design with oil suction pipe loosen screw connection of R3 4 oil suc tion pipe Check for leaks Figure 18 Oil suction pipe ...

Page 44: ...3 01 EN VACUTAP VV Ex 8 Remove bolts and locking washers between top part of on load tap changer head and supporting flange Figure 19 On load tap changer head 9 Lift top part of on load tap changer head off supporting flange Figure 20 On load tap changer head ...

Page 45: ... load tap changer head on the transformer cover 1 Clean sealing surfaces on mounting flange and on load tap changer head place oil resistant gasket on mounting flange Figure 21 Mounting flange and on load tap changer head 2 Position top part of on load tap changer head on mounting flange Figure 22 On load tap changer head ...

Page 46: ...tricts the swivel range of the upper gear unit 5 3 1 3 Connecting on load tap changer to top part of on load tap changer head NOTICE Damage to the on load tap changer A missing or damaged o ring as well as unclean sealing surfaces lead to in sulating fluid escaping and therefore to damage to the on load tap changer Ensure that the o ring is positioned untwisted in the on load tap changer head cove...

Page 47: ...provided and slowly lift on load tap changer from below towards on load tap changer head Under no circumstances should the on load tap changer be lifted up with the fixing bolts Ensure that all supporting flange stud bolts go easily through the mounting holes of the on load tap changer head Figure 23 On load tap changer 2 Screw the top part to the bottom part of the on load tap changer head Figure...

Page 48: ...For design with oil suction pipe connect oil suction pipe screw connec tion Check for leaks Figure 25 Oil suction pipe 4 Screw the on load tap changer head to the mounting flange The tighten ing torque depends on the screw connection elements used Figure 26 On load tap changer head ...

Page 49: ...ts Connect connecting leads without warping or deforming If necessary use an expansion loop for connecting leads 1 Connect tap winding and on load tap changer take off lead in accordance with the connection diagram included with the delivery 2 If connection leads have to cross the open surface of the oil compartment change over selector there must be a clearance of 50 mm between the connecting lea...

Page 50: ...e indicated in the connection diagram supplied with the delivery For multiple column applications with a shared drive link all on load tap changer heads to one another using the horizontal drive shaft parts When actuating the change over selector a higher torque is required 1 Switch the on load tap changer into the desired operating position The di verter switch operation can be heard distinctly 2...

Page 51: ... in the oil compartment reduces the dielectric strength of the insu lating fluid and thus leads to damage to the on load tap changer Within 10 hours of drying seal off oil compartment with on load tap changer head cover Dry on load tap changer in accordance with the following instructions to en sure the dielectric values assured by MR for the on load tap changer If drying in an autoclave the follo...

Page 52: ...g in the oil compartment base before drying so that the kerosene conden sate can drain from the oil compartment 1 Unscrew kerosene drain plug in base of oil compartment counter clock wise The kerosene drain plug cannot be unscrewed all the way Figure 28 Kerosene drain plug 2 NOTICE Remove the on load tap changer head cover 24 screws M10 wrench size 17 with locking washers and store it outside the ...

Page 53: ...load tap changer in transformer tank Dry on load tap changer in accordance with the following instructions to en sure the dielectric values assured by MR on the on load tap changer If you want to dry the on load tap changer in the transformer tank fully as semble the transformer first and then undertake drying If drying in the transformer tank the following methods are possible Vacuum drying Vapor...

Page 54: ...nger in circulating air at a maximum tempera ture of 110 C for a period of at least 20 hours 3 Vacuum dry on load tap changer at between 105 C and maximum 125 C for at least 50 hours 4 Residual pressure of no more than 10 3 bar 5 3 6 2 Vapor phase drying in the transformer tank If you have opened the kerosene drain plug already e g after the trans former ratio test you can begin the drying right a...

Page 55: ...one shared lead Figure 31 Kerosene vapor lead 5 Seal off unused pipe connections and pipe bends with a suitable blank cover Vapor phase drying in the transformer tank 1 Supply kerosene vapor at a temperature of around 90 C Keep this tem perature constant for 3 to 4 hours 2 Increase the kerosene vapor temperature by approx 10 C hour to the de sired final temperature of max 125 C at the on load tap ...

Page 56: ...amage to the on load tap changer Use insulating fluids that meet the requirements in accordance with IEC 60296 If approved by the transformer manufacturer you can use synthetic es ters in accordance with IEC 61099 approved by Maschinenfabrik Rein hausen GmbH After drying completely fill the oil compartment diverter switch insert fitted with oil again as soon as possible so that an impermissible am...

Page 57: ...l compartment of the on load tap changer is completely filled with insulating fluid Only switch the on load tap changer from one operating position to the next via the upper gear unit You can use a short tube diameter 25 mm with screwed in coupling bolt diameter 12 mm with a hand wheel or crank for this for example When using a drill do not exceed a maximum speed of 250 rpm Always check the operat...

Page 58: ... to crank the drive shaft of the upper gear unit for 2 5 revolutions in the same direction in order to correctly complete the tap change operation 3 Perform the transformer ratio test 4 Repeat the transformer ratio test in all operating positions 5 Switch the on load tap changer into adjustment position see the accom panying connection diagram for the on load tap changer 5 4 Installing on load tap...

Page 59: ...ertically into supporting structure maximum 1 deviation from the vertical so that the on load tap changer reaches its final installation height and only has to be raised a maximum of 5 to 20 mm after fitting the bell type tank Figure 34 Supporting structure 3 Temporarily fasten on load tap changer to supporting structure The sup porting flange has through holes for this purpose Figure 35 Temporary...

Page 60: ...s 11 mm diameter for M10 screws see appendix Section 9 4 Page 138 5 4 3 Performing transformer ratio test before drying NOTICE Damage to the on load tap changer Damage to the on load tap changer due to transformer ratio test being in correctly performed Do not perform more than 250 tap change operations on the on load tap changer If more than 250 tap change operations are to be performed completel...

Page 61: ...com partment if the on load tap changer is to be dried with kerosene in the trans former tank After drying the diverter switch insert must be removed the kerosene drain plug in the oil compartment closed and the diverter switch insert refitted 5 4 4 Performing DC resistance measurement on transformer The measured DC current is normally restricted to 10 of the rated current of the measured transfor...

Page 62: ...ting vacuum drying in the autoclave you must remove the on load tap changer head cover and on load tap changer accessories 1 NOTICE Remove the on load tap changer head cover 24 screws M10 wrench size 17 with safety elements and store it outside the autoclave If this is not done the on load tap changer head cover may be damaged 2 NOTICE Remove on load tap changer accessories and store outside au to...

Page 63: ...r may be damaged 3 NOTICE Remove on load tap changer accessories and store outside au toclave motor drive unit drive shaft protective relay bevel gear temper ature sensor If this is not done the on load tap changer accessories may be damaged Vapor phase drying in the autoclave 1 Supply kerosene vapor at a temperature of around 90 C Keep this tem perature constant for 3 to 4 hours 2 Increase the ke...

Page 64: ...ief device pressure monitoring device before removing the on load tap changer head cover Do not operate any electrical devices during the work e g risk of sparks from impact wrench NOTICE Damage to the on load tap changer Small parts in the oil compartment may block the diverter switch insert thereby damaging the on load tap changer Ensure that parts do not fall into the oil compartment Check that...

Page 65: ... locking washers on on load tap changer head cover Figure 38 On load tap changer head cover 5 Remove on load tap changer head cover Figure 39 On load tap changer head cover 6 For design with oil suction pipe loosen screw connection of R3 4 oil suc tion pipe Check for leaks Figure 40 Oil suction pipe ...

Page 66: ...N VACUTAP VV Ex 7 Remove bolts and locking washers between top part of on load tap changer head and supporting flange Figure 41 On load tap changer head 8 Lift top part of on load tap changer head off supporting flange Figure 42 Top part of on load tap changer head ...

Page 67: ...necting the on load tap changer to the top part of the on load tap changer head 5 4 7 1 Attaching bell type tank 1 Clean sealing surface of supporting flange place o ring on supporting flange Figure 43 Supporting flange with o ring 2 Lift the bell type tank over the active part of the transformer Figure 44 Bell type tank ...

Page 68: ...load tap changer head on bell type tank 1 Clean sealing surfaces on mounting flange and on load tap changer head place oil resistant gasket on mounting flange Figure 45 Mounting flange and on load tap changer head 2 Position top part of on load tap changer head on mounting flange Figure 46 On load tap changer head ...

Page 69: ...tricts the swivel range of the upper gear unit 5 4 7 3 Connecting on load tap changer to top part of on load tap changer head NOTICE Damage to the on load tap changer A missing or damaged o ring as well as unclean sealing surfaces lead to in sulating fluid escaping and therefore to damage to the on load tap changer Ensure that the o ring is positioned untwisted in the on load tap changer head cove...

Page 70: ...provided and slowly lift on load tap changer from below towards on load tap changer head Under no circumstances should the on load tap changer be lifted up with the fixing bolts Ensure that all supporting flange stud bolts go easily through the mounting holes of the on load tap changer head Figure 47 On load tap changer 2 Screw the top part to the bottom part of the on load tap changer head Figure...

Page 71: ...For design with oil suction pipe connect oil suction pipe screw connec tion Check for leaks Figure 49 Oil suction pipe 4 Screw the on load tap changer head to the mounting flange The tighten ing torque depends on the screw connection elements used Figure 50 On load tap changer head ...

Page 72: ...If you want to dry the on load tap changer in the transformer tank fully as semble the transformer first and then undertake drying If drying in the transformer tank the following methods are possible Vacuum drying Vapor phase drying As an alternative to drying the on load tap changer in the transformer tank it can also be dried in an autoclave 5 4 8 1 Vacuum drying in the transformer tank The on l...

Page 73: ...nger in circulating air at a maximum tempera ture of 110 C for a period of at least 20 hours 3 Vacuum dry on load tap changer at between 105 C and maximum 125 C for at least 50 hours 4 Residual pressure of no more than 10 3 bar 5 4 8 2 Vapor phase drying in the transformer tank If you have opened the kerosene drain plug already e g after the trans former ratio test you can begin the drying right a...

Page 74: ...one shared lead Figure 54 Kerosene vapor lead 5 Seal off unused pipe connections and pipe bends with a suitable blank cover Vapor phase drying in the transformer tank 1 Supply kerosene vapor at a temperature of around 90 C Keep this tem perature constant for 3 to 4 hours 2 Increase the kerosene vapor temperature by approx 10 C hour to the de sired final temperature of max 125 C at the on load tap ...

Page 75: ...amage to the on load tap changer Use insulating fluids that meet the requirements in accordance with IEC 60296 If approved by the transformer manufacturer you can use synthetic es ters in accordance with IEC 61099 approved by Maschinenfabrik Rein hausen GmbH After drying completely fill the oil compartment diverter switch insert fitted with oil again as soon as possible so that an impermissible am...

Page 76: ...l compartment of the on load tap changer is completely filled with insulating fluid Only switch the on load tap changer from one operating position to the next via the upper gear unit You can use a short tube diameter 25 mm with screwed in coupling bolt diameter 12 mm with a hand wheel or crank for this for example When using a drill do not exceed a maximum speed of 250 rpm Always check the operat...

Page 77: ...ically connecting the temperature sensor Size the cable for the electrical connection of the temperature sensors such that you can turn the sensors if necessary when mounting the drive shaft Electrically connect the temperature sensors in accordance with the con nection diagram provided 5 5 2 Installing protective relay in piping and connecting WARNING Danger of explosion Explosive gases in the pr...

Page 78: ... selecting the cir cuit breaker type All circuits and suitable equipment such as isolating de vices must satisfy the requirements on explosion protection applicable in the respective potentially explosive area In addition observe the following It must be easy for the operator to access the isolating device The isolating device must be labeled for the device and the circuits to be isolated The isol...

Page 79: ...act positions for checking electrical continuity are shown in the dimen sional drawing provided 1 Loosen the three screws on the terminal box cover and lift off the terminal box cover Figure 57 Terminal box cover 2 Remove the slotted head screw for potential tie in and remove the termi nal box cover with wire Figure 58 Terminal box cover NOTICE Damage to protective relay Damage to protective relay...

Page 80: ...3 01 EN VACUTAP VV Ex 3 Press OFF test button ð Flap valve is inclined The red indicator is not visible Figure 59 OFF position 4 Press OPERATION test button ð Flap valve is vertical The red indicator appears in the viewing window Figure 60 OPERATION position ...

Page 81: ...r 5 5 2 3 Installing protective relay in piping Ensure the following for installation and proper function of the protective re lay 1 Ensure that there are no foreign bodies in the piping or in the oil conserva tor 2 Install protective relay such that it can be easily accessed for subsequent maintenance work 3 Install protective relay with good support and free from vibrations 4 The test buttons mu...

Page 82: ...elay to the oil conservator must be routed with an inclination of at least 2 1 2 to ensure the switching gases can escape freely 8 The protective relay is intended for a horizontal operating position in close proximity to the on load tap changer head A positive inclination of up to 5 from the horizontal is permitted in the direction toward the conservator An inclination of up to 5 from the vertica...

Page 83: ...en GmbH 2020 83 4983703 01 EN VACUTAP VV Ex 9 The reference arrow on the terminal box cover must point toward the on load tap changer s oil conservator Figure 64 Reference arrow pointing towards the on load tap changer s oil conservator ...

Page 84: ...r an NC or NO contact in the following variants 2 x NC contact 2 x NO contact 1 x NC contact and 1x NO contact WARNING Risk of death or severe injury Risk of death or severe injury due to improper electrical connection of the protective relay Loop the protective relay into the tripping circuit of the circuit breakers of the transformer to be protected so that the transformer is immediately de ener...

Page 85: ...d as follows 1 Connect protective conductor with cable cross section of 1 4 mm2 to cylinder head screw 2 Take off MR dummy plug Figure 66 Dummy plug 3 Insert explosion certified cable bushing into tapped hole on side of termi nal box 4 Loosen the three screws on the terminal box cover and lift off the terminal box cover Figure 67 Terminal box cover ...

Page 86: ...r the protective cover and take off the protective cover Figure 69 Terminal box cover and protective cover 7 Guide explosion certified cable through cable bushing and into protective relay Ensure that the cable gland is well connected and sealed 8 Connect electric cables with cable cross section of 1 4 mm2 to connec tion terminals in accordance with connection diagram 9 Insert the protective cover...

Page 87: ...ng the slotted head screw Figure 70 Terminal box cover 11 Attach the terminal box cover and secure with screws Figure 71 Terminal box cover 5 5 3 Fitting motor drive unit Fit motor drive unit to transformer as described in relevant MR operating instructions for motor drive unit 5 5 4 Fitting drive shaft Observe the following during mounting ...

Page 88: ... of the drive and the on load tap changer or de ener gized tap changer cannot be guaranteed The shaft ends to be connected must be exactly aligned Permitted axial displacement Minor axial displacement can be tolerated as long as it does not exceed 35 mm per 1 000 mm square tube length that corresponds to 2 Figure 72 Permitted maximum axial displacement of vertical drive shaft ...

Page 89: ...ing square tubes telescopic protective tubes and protective cover The square tubes telescopic protective tubes and protective cover are sup plied in overlengths graded standard lengths You must cut these parts to the required size before mounting on the transformer In rare cases you also have to cut the inner tube of the telescopic protective tube to the desired length The maximum total drive shaf...

Page 90: ...s 1 CAUTION Switch off motor protective switch Q1 in the motor drive unit position O If this is not done the motor drive unit may be started in advertently and cause injuries 2 Screw down the bevel gear for fastening on the transformer on both sides with the contact washers provided to ensure permanent grounding Screws are not included in the scope of supply Figure 74 Bevel gear ...

Page 91: ...sen GmbH 2020 91 4983703 01 EN VACUTAP VV Ex 3 Determine dimension A between shaft end of drive and shaft end of bevel gear Shorten the square tube to length of A 179 mm taking the insulator into account Figure 75 Shortening square tube ...

Page 92: ...the cut surfaces on the square tube Figure 76 Deburring cut surfaces 5 Screw down the double coupling bracket with the insulator supplied and the square tube Mount the insulator on the side facing the drive Figure 77 Screwing down the square tube and the insulator with double coupling part ...

Page 93: ...til the stop is reached Figure 78 Sliding the coupling part onto the insulator 7 Insert the coupling bolt into the shaft end of the drive Grease the coupling part coupling bolt and shaft end e g ISOFLEX TOPAS L32 Slide the square tube with the coupling part onto the shaft end Figure 79 Sliding the square tube with the coupling part onto the shaft end ...

Page 94: ... 80 Attaching the square tube to the drive 9 Pivot the square tube away from the axis Figure 81 Pivoting the square tube away from the axis 10 When installing the telescopic protective tube shorten the inner tube on the side without slots if necessary The minimum dimension for overlap ping the two protective tubes is 100 mm ...

Page 95: ...ed in order to slide easily in the outer tube Figure 82 Deburring the inner tube Dimension A distance between the shaft end of the drive and the shaft end of bevel gear Inner tube Outer tube 170 mm 190 mm Shorten to 200 mm 200 mm 191 mm 1130 mm Dimension A 20 mm 200 mm 1131 mm 1598 mm 700 mm 1150 mm 1 599 mm 2 009 mm 1150 mm 1 150 mm ...

Page 96: ...n GmbH 2020 96 4983703 01 EN VACUTAP VV Ex 11 For the separate grounding with 110 mm spacing viewed from the slot ted side drill an 11 mm diameter hole in the inner tube Figure 83 Producing grounding hole on the telescopic protective tube ...

Page 97: ...e outer tube over the inner tube When doing so make sure that the non slotted side of the inner tube is facing upwards Slide the tele scopic protective tube onto the square tube Then slide the hose clips over the telescopic protective tube Figure 84 Sliding on the telescopic protective tube ...

Page 98: ...1 EN VACUTAP VV Ex 13 Place the adapter ring over the bearing collar of the bevel gear and slide upwards Insert the coupling bolt into the shaft end of the bevel gear Pivot the square tube back to the axis Figure 85 Fitting the adapter ring and the coupling bolt ...

Page 99: ...ease the coupling brackets coupling bolt and shaft end e g ISOFLEX TOPAS L32 and secure the square tube with the coupling brackets on the bevel gear Set a unilateral axial clearance of 3 mm between the coupling bolt and the upper coupling piece Figure 86 Mounting the coupling brackets ...

Page 100: ...plied screw with contact washers to establish a connection between the bottom protective tube inner tube and the functional ground Due to the risk of collision with the screw head fit the fixing screw for the grounding cable from the inside Figure 87 Screwing down the grounding cable on the telescopic protective tube ...

Page 101: ... Attach the bottom protective tube inner tube with a hose clip to the bearing collar of drive Then slide the upper protective tube outer tube over the adapter on the bevel gear Secure the upper protective tube to the second hose clip at top end Figure 88 Mounting the protective tube ...

Page 102: ... Fitting horizontal drive shaft with insulator Aligning upper gear unit on the on load tap changer head In order to correctly install the horizontal drive shaft under certain circum stances you may have to first align the upper gear unit such that the horizon tal drive shaft is flush with the shaft end of the upper gear unit To do so proceed as follows 1 NOTICE Damage to the on load tap changer du...

Page 103: ... segments 3 NOTICE Align gear unit such that the horizontal drive shaft is flush with the drive shaft of the gear unit While aligning the gear unit turn the unit s drive shaft such that its output shaft retains its original position Failure to do so may result in damage to the de energized tap changer and trans former when starting up Figure 91 Aligning gear unit ...

Page 104: ...and that the pressure ring segments are firmly in contact with the gear unit housing Figure 92 Securing pressure ring segments Fitting the horizontal drive shaft To mount the horizontal drive shaft proceed as follows 1 Calculate dimension A between the shaft end of the upper gear unit and the shaft end of the bevel gear and shorten the square tube to length A 179 mm taking the insulator into accou...

Page 105: ...ut down the protective cover to B 2 mm and deburr the cut edges Figure 94 Shortening and deburring the protective cover 3 For the separate grounding with 110 mm spacing from the bevel gear drill an 11 mm diameter hole in the protective cover Protect the protective cover against corrosion with a coat of paint Figure 95 Producing the grounding hole on the protective cover ...

Page 106: ...bracket with the insulator supplied and the square tube Mount the insulator on the side facing the bevel gear Figure 96 Screwing down the square tube and the insulator with double coupling part 5 Slide the loosely screwed together coupling part onto the insulator until the stop is reached Figure 97 Coupling parts ...

Page 107: ...ar e g ISOFLEX TOPAS L32 and insert the coupling bolt into shaft end Thread the hose clip onto the square tube and slide the square tube with the coupling part onto the shaft end Figure 98 Sliding the square tube with the coupling part onto the shaft end 7 Secure the square tube onto the bevel gear Figure 99 Securing the square tube on the bevel gear ...

Page 108: ... the shaft end of the upper gear unit e g ISOFLEX TOPAS L32 and insert the coupling bolt into the shaft end Secure the square tube with the coupling brackets on the upper gear unit Set a unilateral axial clearance of 3 mm between the coupling bolt and the upper coupling piece Figure 100 Secure the square tube on the upper gear unit ...

Page 109: ...2020 109 4983703 01 EN VACUTAP VV Ex 9 Attach the shortened protective cover to the housing lugs on the on load tap changer head and the bevel gear Secure each end of the protective cover with a hose clip Figure 101 Fitting the protective cover ...

Page 110: ...ap changer sets and combinations For two column and three column on load tap changer models the individ ual on load tap changer columns are driven by a common motor drive unit You must couple the on load tap changer heads above the transformer cover together and ensure synchronous switching of the on load tap changer columns Proceed as follows 1 Check that the operating positions of all on load ta...

Page 111: ... heads Individ ually couple each on load tap changer Start with the on load tap changer which is closest to the motor drive unit 9 NOTICE After installing all drive shafts continue cranking another 2 5 revolutions counter clockwise on the drive shaft of the upper gear unit to correctly complete the tap change operation An incomplete tap change operation may damage the on load tap changer 10 Switch...

Page 112: ...uctive and grounded hoses pipes and pump equipment that are approved for flammable liquids WARNING Danger of explosion Overloading the on load tap changer can lead to explosion Spraying hot in sulating fluid and flying parts can lead to death and serious injuries Prop erty damage is highly probable Ensure that the on load tap changer is not overloaded Ensure use of the on load tap changer in accor...

Page 113: ... Remove screw cap on air vent valve E1 on the on load tap changer head cover Figure 103 Air vent valve E1 3 Use screwdriver to lift valve tappet on air vent valve E1 and bleed on load tap changer head Figure 104 Valve tappet 4 Seal air vent valve E1 with screw cap tightening torque 10 Nm ...

Page 114: ...2 Open vent screw and bleed piping 3 Close vent screw 4 Seal vent screw with screw cap 6 1 2 Grounding the on load tap changer If necessary reduce the stated tightening torque according to the grounding line used 1 Ground the on load tap changer To do this only connect the grounding terminal on the on load tap changer head with the transformer cover Figure 106 Grounding terminal on on load tap cha...

Page 115: ...sulating fluid and that the oil compartment of the on load tap changer is completely filled with insulating fluid Prior to commissioning the transformer check whether the motor drive unit and on load tap changer are correctly coupled and that the motor drive unit functions correctly Tests on the motor drive unit 1 Perform function checks as described in relevant MR operating instruc tions for moto...

Page 116: ...ral connection point estab lishment of suitable reference earth Disconnect all electronic components before the high voltage test Before a dielectric test of the wiring remove all devices with a withstand voltage of 1000 V Remove leads used for testing before the high voltage test as these func tion as antennas Wherever possible route the measurement leads and data leads sepa rately to the energy ...

Page 117: ...allation site 6 2 2 Transport with full transformer tank and without oil conservator Attach a connecting lead between the on load tap changer s oil compartment and the transformer tank if the transformer has been transported with a full tank and without an oil conservator Establish the connecting lead on the on load tap changer head between connections E2 and one of the free pipe connections R S o...

Page 118: ...ent valve E1 on the on load tap changer head 3 Discharge the gas from under the on load tap changer cover Ensure suf ficient fresh air e g in transformer cells and work tents when doing so 4 Once the gas has been discharged and the insulating fluid is flowing out of the air vent valve close the air vent valve and close the stop cock be tween the oil conservator and oil compartment 5 Open air vent ...

Page 119: ...p changer head 3 Drain off the gas from under the on load tap changer cover Ensure suffi cient fresh air for example in transformer cells and work tents 4 Once the gas has been drained off and the oil is flowing out of the air vent valve close this valve and close the stop cock between the oil conserva tor and oil compartment 5 Open air vent valve again and drain off around 5 10 liters of oil via ...

Page 120: ...d NOTICE Damage to the on load tap changer Unsuitable insulating fluids cause damage to the on load tap changer Use insulating fluids that meet the requirements in accordance with IEC 60296 If approved by the transformer manufacturer you can use synthetic es ters in accordance with IEC 61099 or natural esters in accordance with IEC 62770 approved by Maschinenfabrik Reinhausen GmbH 1 Establish a co...

Page 121: ...ple from the oil compartment 4 Record the temperature of the sample immediately after the sample is taken 5 Determine the dielectric strength and water content at a sample tempera ture of 20 C 5 C The dielectric strength and water content must comply with the limit values Section 8 3 Page 134 specified in the technical data 6 3 2 Bleeding on load tap changer head and suction pipe 6 3 2 1 Bleeding ...

Page 122: ... Remove screw cap on air vent valve E1 on the on load tap changer head cover Figure 111 Air vent valve E1 3 Use screwdriver to lift valve tappet on air vent valve E1 and bleed on load tap changer head Figure 112 Valve tappet 4 Seal air vent valve E1 with screw cap tightening torque 10 Nm ...

Page 123: ...l vent screw with screw cap 6 3 3 Checking motor drive unit NOTICE Damage to the on load tap changer de energized tap changer Damage to the on load tap changer de energized tap changer due to actu ation of the on load tap changer de energized tap changer without insulat ing fluid Ensure that the selector de energized tap changer is fully immersed in insulating fluid and that the oil compartment of...

Page 124: ...pled and that the motor drive unit functions correctly Tests on the motor drive unit 1 Perform function checks as described in relevant MR operating instruc tions for motor drive unit 2 NOTICE An incorrectly coupled motor drive unit will lead to damage to the on load tap changer Undertake trial tap change operations across the entire range of settings Ensure that in each operating position the tap...

Page 125: ...f the circuit breaker ü The protective relay and additional protective devices are looped into the circuit breaker s tripping circuit ü The motor drive unit and all protective devices are functioning correctly and are ready for use ü The oil compartment of the on load tap changer is completely filled with insulation fluid ü All stop cocks between on load tap changer and oil conservator of the on l...

Page 126: ... when protective relay or other protective devices have been tripped Do not use the equipment again until you are sure there is no damage to the on load tap changer or transformer NOTICE Damage to motor drive unit Damage to the motor drive unit due to condensate in protective housing of motor drive unit Always keep protective housing of the motor drive unit tightly closed In the event of operation...

Page 127: ...nger not changing tap position sluggish ness Raise keys Lower keys not working no audible di verter switch action Contact MR No change in voltage on transformer despite change in po sition on motor drive unit Contact MR Tap position indicator on motor drive unit and on load tap changer different Contact MR Noises on drive shaft or motor drive unit when changing tap position Ensure proper mounting ...

Page 128: ...sted Be sure to contact Maschinenfabrik Reinhausen to check on load tap changer and transformer if the protective relay has tripped Only use the equipment again when you are sure there is no damage to the on load tap changer or transformer When the circuit breakers have been tripped by the protective relay proceed as follows 1 Establish time of tripping 2 Determine operating position of on load ta...

Page 129: ... the instant of tripping ð Was the on load tap changer moved immediately before or during trip ping ð Did any other protective devices of the transformer respond at the in stant of tripping ð Were switching operations in the network being carried out at the in stant of tripping ð Were overvoltages registered at the instant of tripping 3 Take further action in agreement with Maschinenfabrik Reinhau...

Page 130: ...strength See technical data TD 61 General Section Alternative insulating fluids Synthetic ester liquid IEC 61099 on request Installation height of the oil conservator See technical data TD 61 General Section Installation height above sea level See technical data TD 61 General Section Table 15 Permissible ambient conditions 8 2 Technical data for protective relay The technical data for the protecti...

Page 131: ...ighest current 2 A at 125 V with cos φ 0 6 Maximum switched current AC highest voltage 1 6 A at 250 V with cos φ 0 6 Switching operations 1 000 cycles Table 18 Switching capacity switching load on an off Dielectric strength AC dielectric strength between all volt age carrying connections and the grounded parts 2 500 V 50 Hz test duration 1 minute AC dielectric strength between the opened contacts ...

Page 132: ...tween all volt age carrying connections and the grounded parts 2 500 V 50 Hz test duration 1 minute AC dielectric strength between the opened contacts 2 000 V 50 Hz test duration 1 minute Table 22 Dielectric strength Ambient conditions Ambient temperature Ta 25 C 50 C Oil temperature 130 C Air pressure Corresponds to 0 m 4 000 m above mean sea level Table 23 Ambient conditions 8 2 1 Protective rel...

Page 133: ...3 4983703 01 EN VACUTAP VV Ex 8 2 2 Tests Electrical safety IEC 61010 1 Safety requirements for electrical measurement and con trol and regulation equipment and laboratory instruments Overvoltage category III Contamination level 2 Table 24 Electrical safety ...

Page 134: ...etermined based on IEC 60422 IEC 61203 and IEEE C57 147 Limit values for insulating fluids in ac cordance with IEC 60296 Ud H2O When commissioning the transformer for the first time 60 kV 2 5 mm 12 ppm During operation 30 kV 2 5 mm 30 ppm After maintenance 50 kV 2 5 mm 15 ppm Table 25 Insulating fluids in accordance with IEC 60296 Limit values for synthetic esters in ac cordance with IEC 61099 Ud ...

Page 135: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 135 4983703 01 EN VACUTAP VV Ex 9 Drawings 9 1 External view 737774 ...

Page 136: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 136 4983703 01 EN VACUTAP VV Ex 9 2 On load tap changer head without oil suction pipe 898863 ...

Page 137: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 137 4983703 01 EN VACUTAP VV Ex 9 3 On load tap changer head with oil suction pipe 737060 ...

Page 138: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 138 4983703 01 EN VACUTAP VV Ex 9 4 Installation drawing 738902 ...

Page 139: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 139 4983703 01 EN VACUTAP VV Ex 9 5 Oil suction pipe 739172 ...

Page 140: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 140 4983703 01 EN VACUTAP VV Ex 9 6 Dimensions of oil suction pipe not supplied by MR 734342 ...

Page 141: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 141 4983703 01 EN VACUTAP VV Ex 9 7 Tracing template for on load tap changer head 893787 ...

Page 142: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 142 4983703 01 EN VACUTAP VV Ex 9 8 Mounting drawing 898866 ...

Page 143: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 143 4983703 01 EN VACUTAP VV Ex 9 9 Mounting with bell type tank installation 899110 ...

Page 144: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 144 4983703 01 EN VACUTAP VV Ex 9 10 Position of on load tap changer 899409 ...

Page 145: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 145 4983703 01 EN VACUTAP VV Ex 9 11 Position of connection contacts 899051 ...

Page 146: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 146 4983703 01 EN VACUTAP VV Ex 9 12 Tap change supervisory control 733469 ...

Page 147: ...9 Drawings Maschinenfabrik Reinhausen GmbH 2020 147 4983703 01 EN VACUTAP VV Ex 9 13 Bevel gear CD 6400 dimensional drawing 892916 ...

Page 148: ...kV 2 5 mm maximum electrical field strength without a breakdown arc IEC The International Electrotechnical Commission IEC for short is involved in the preparation and publication of international standards for electri cal electronic and related technologies IP Ingress protection MR Maschinenfabrik Reinhausen GmbH NC Normally Closed contact NO Normally Open contact ...

Page 149: ......

Page 150: ...fabrik Reinhausen GmbH Falkensteinstrasse 8 93059 Regensburg 49 0 941 4090 0 sales reinhausen com www reinhausen com 4983703 01 EN VACUTAP VV Ex 08 20 Maschinenfabrik Reinhausen GmbH 2020 THE POWER BEHIND POWER ...

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MR VACUTAP VV-Ex, Installation And Commissioning Instructions

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